Composite fabrics

ABSTRACT

A composite fabric is provided. The composite fabric includes a fabric substrate and a material layer. The material layer, which includes a mixture, is on the fabric substrate. The mixture includes an amine-containing polymer and a powder. The powder is in the amine-containing polymer. The amine-containing polymer includes polyethylenimine, derivatives of polyethylenimine, or a combination thereof. The powder includes doped zinc oxide, indium tin oxide, doped indium tin oxide, or a combination thereof. The amine-containing polymer has an amount of 0.1 to 40 parts by weight base on 100 parts by weight of the powder.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the priority benefits of U.S. provisional application Ser. No. 62/276,412, filed on Jan. 8, 2016. The entirety of each of the above-mentioned patent application is hereby incorporated by reference herein and made a part of this specification.

TECHNICAL FIELD

The technical field relates to composite fabrics.

BACKGROUND

A fabric exhibiting warmth-retention properties is principally made of wool, cotton, and chemical fibers. Thickening the fabric can increase the warmth-retention properties of the fabric, but this results in decreasing the comfort of a wearer. It is necessary to develop a warm, lightweight, and comfortable cloth.

SUMMARY

The disclosure provides a composite fabric that may include a fabric substrate; and a material layer, wherein the material layer is on the fabric substrate and the material layer comprises a mixture. The mixture comprises an amine-containing polymer and a powder. The amine-containing polymer comprises polyethylenimine, derivatives of polyethylenimine, or a combination thereof. The derivatives of polyethylenimine comprise ethoxyl group terminated polyethylenimine, carboxylic acid group terminated polyethylenimine, isocyanate group terminated polyethylenimine, or a combination thereof. The powder is in the amine-containing polymer and comprises doped zinc oxide, indium tin oxide, doped indium tin oxide, or a combination thereof. The amine-containing polymer has an amount of 0.1 to 40 parts by weight base on 100 parts by weight of the powder.

A detailed description is given in the following embodiments.

DETAILED DESCRIPTION

In the following detailed description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the disclosed embodiments. It will be apparent, however, that one or more embodiments may be practiced without these specific details.

According to an embodiment of the disclosure, a composite fabric is provided. The composite fabric of the disclosure includes a fabric substrate and a material layer on the fabric substrate. The composite fabric has good infrared (IR)-induced temperature-rising performance and good infrared absorptivity. The material layer can include a mixture. The mixture can include an amine-containing polymer and a powder.

According to an embodiment of the disclosure, the powder of the mixture is dispersed in the amine-containing polymer and a solvent to form a colloidal mixture. According to an embodiment of the disclosure, a portion of the powder may aggregate to form colloids in the colloidal mixture. Then the colloidal mixture is coated on the fabric substrate and then dried to provide a composite fabric. The solvent can be reduced or removed in the drying process. According to an embodiment of the disclosure, parts of the colloidal mixture may soak into the fabric substrate, which results in the formation of a composite layer between the fabric substrate and the material layer when the colloidal mixture is coated onto the fabric substrate. The composite layer includes parts of the colloidal mixture and parts of the fabric substrate. According to an embodiment of the disclosure, when the colloidal mixture is being coated onto the fabric substrate, the colloidal mixture is on the surface of the fabric substrate and almost none of the colloidal mixture soaks into the fabric substrate. The processability of the colloidal mixture can optionally be adjusted to form or not to form a composite layer, depending on the needs of the specific application. In order to coat the fabric substrate with the colloidal mixture, many methods may be used. It is possible to use various processes including dip coating, die coating, roll coating, comma coating, or a combination thereof.

According to an embodiment of the disclosure, the colloidal mixture can optionally include a polymer matrix to form a mixture solution. The mixture solution is covered (e.g., coated) on a releasing substrate (e.g., releasing paper), followed by drying, and then the releasing substrate is detached to provide a film. The solvent can be reduced or removed in the drying process. In order to coat the releasing substrate with the mixture solution, many methods may be used. It is possible to use various processes including dip coating, die coating, roll coating, comma coating, or a combination thereof. The film is transferred from the releasing substrate to the fabric substrate to form the composite fabric. According to an embodiment of the disclosure, the way to transfer the film can be heat press laminating (at about 60° C. to 150° C.).

According to an embodiment of the disclosure, the powder includes doped zinc oxide, indium tin oxide, doped indium tin oxide, or a combination thereof. The doped element of doped zinc oxide and doped indium tin oxide comprises a Group IIIB element (e.g., gallium, aluminum, or a combination thereof), iron, or a combination thereof. The doped element of doped zinc oxide or doped indium tin oxide has an amount of about 0.1 to about 20 parts by weight (e.g., about 1 to about 6 parts by weight) base on 100 parts by weight of zinc oxide or indium tin oxide. According to an embodiment of the disclosure, if there is too little of the doped element, this may possibly cause a decrease of the infrared-induced temperature-rising and the infrared absorptivity.

According to an embodiment of the disclosure, the particle size of the powder may vary, depending on the needs of the specific application. The particle size of the powder may range from about 10 nm to about 200 nm, for example from about 20 nm to about 100 nm. The powder has an amount of about 0.1 to about 15 parts by weight (e.g., about 1 to about 10 parts by weight) base on 100 parts by weight of the fabric substrate. If there is too much powder, the washability of the material layer of the composite fabric may be reduced. If there is not enough powder, the infrared-induced temperature-rising and the infrared absorptivity of the composite fabric may be reduced.

According to an embodiment of the disclosure, the amine-containing polymer can include polyethylenimine, derivatives of polyethylenimine, or a combination thereof. The derivatives of polyethylenimine can include ethoxyl group terminated polyethylenimine, carboxylic acid group terminated polyethylenimine, isocyanate group terminated polyethylenimine, or a combination thereof. The polyethylenimine or the derivatives of polyethylenimine can be linear, branched, dendrimer, or a combination thereof. The weight average molecular weight of the amine-containing polymer is from about 500 to about 100000 (e.g., about 1500 to about 12000). If the weight average molecular weight is too high, the viscosity of the colloidal mixture tends to be too high. If the weight average molecular weight is too low, this may lead to sedimentation of the powder. According to an embodiment of the disclosure, the amine-containing polymer has an amount of about 0.1 to about 40 parts by weight (e.g., about 1 to about 20 parts by weight) base on 100 parts by weight of the powder. If there is too much amine-containing polymer, the viscosity of the colloidal mixture tends to be too high. If there is too little amine-containing polymer, this may lead to sedimentation of the powder.

According to an embodiment of the disclosure, the solvent can include dimethylacetamide, dimethylformamide, dimethyl sulfoxide, or a combination thereof. According to an embodiment of the disclosure, the solvent has an amount of about 20 to about 90 parts by weight base on 100 parts by weight of the colloidal mixture. If there is too much solvent, this may lead to sedimentation of the powder. If there is not enough solvent, the processability of the colloidal mixture in the coating process may be decreased.

According to an embodiment of the disclosure, the average particles size of the colloids in the colloidal mixture range from about 150 nm to about 390 nm, and the zeta potential of the colloids in the colloidal mixture range from about 7 mV to about 20 mV. If the average particles size of the colloids in the colloidal mixture is too large, the dispersion of the colloids in the colloidal mixture tends to be unstable or non-uniform. If the zeta potential of the colloids in the colloidal mixture is too low, the dispersion of the colloids in the colloidal mixture tends to be unstable.

According to an embodiment of the disclosure, the polymer matrix can include polyurethane, polyacrylate, or a combination thereof. The polymer matrix has an amount of about 50 to about 10000 parts by weight (e.g., about 100 to about 1000 parts by weight) base on 100 parts by weight of the powder.

According to an embodiment of the disclosure, the fabric substrate can be polyethylene fiber cloth, polypropylene fiber cloth, polyamide fiber cloth, polyester fiber cloth, cotton fiber cloth, rayon fiber cloth, acetyl fiber cloth, wool fiber cloth, or a combination thereof.

According to an embodiment of the disclosure, the composite fabric has an infrared absorption of the spectrum at about 780 nm to about 1000000 nm (e.g., at about 1000 nm to about 2500 nm).

According to an embodiment of the disclosure, the composite fabric can have various functions according to the use of different fabric substrates. For example, the composite fabric can be anti-ultraviolet, anti-bacterial, antistatic, cationic dyeable, high amine value for low-temperature dyeing, shaped cross-section moisture wicking, hollow fiber for insulation.

Below, exemplary embodiments will be described in detail so as to be easily realized by a person having ordinary knowledge in the art. The disclosure concept may be embodied in various forms without being limited to the exemplary embodiments set forth herein. Descriptions of well-known parts are omitted for clarity.

Preparation of Colloidal Mixtures

Example 1

100 g of gallium doped zinc oxide (Ga/Zn=5.0 wt %) was dispersed into 5 g of polyethylenimine (having a weight average molecular weight of about 10000) and 400 g of dimethylacetamide to form a colloidal mixture. The colloids in the colloidal mixture had an average particle size of about 199.5 nm and a zeta potential of about 15 mV. There was no sedimentation of gallium doped zinc oxide for at least 2 hours (even for 6 hours) at room temperature (25° C.).

Example 2

100 g of gallium doped zinc oxide (Ga/Zn=5.0 wt %) was dispersed into 5 g of polyethylenimine (having a weight average molecular weight of about 1800) and 400 g of dimethylacetamide to form a colloidal mixture. The colloids in the colloidal mixture had an average particle size of about 310.8 nm and a zeta potential of about 11 mV. There was no sedimentation of gallium doped zinc oxide for at least 2 hours (even for 6 hours) at room temperature (25° C.).

Comparative Example 1

100 g of gallium doped zinc oxide (Ga/Zn=5.0 wt %) was dispersed into 5 g of polyacrylic acid (having a weight average molecular weight of about 8000) and 400 g of dimethylacetamide to form a colloidal mixture. The colloids in the colloidal mixture had an average particle size of about 227.7 nm and a zeta potential of about 4.8 mV. The colloidal mixture gelled in 2 hours at room temperature (25° C.).

Comparative Example 2

20 g of gallium doped zinc oxide (Ga/Zn=5.0 wt %) was dispersed into 1 g of oleyl phosphate and 80 g of dimethylacetamide to form a colloidal mixture. The colloids in the colloidal mixture had an average particle size of about 493.5 nm and a zeta potential of about 2.2 mV. The colloidal mixture gelled in 2 hours at room temperature (25° C.).

Comparative Example 3

20 g of gallium doped zinc oxide (Ga/Zn=5.0 wt %) was dispersed into 1 g of oleylamide and 80 g of dimethylacetamide to form a colloidal mixture. The colloids in the colloidal mixture had an average particle size of about 642.5 nm and a zeta potential of about 5.0 mV. The colloidal mixture gelled in 2 hours at room temperature (25° C.).

Comparative Example 4

20 g of gallium doped zinc oxide (Ga/Zn=5.0 wt %) was dispersed into 1 g of dimethylacetamide to form a colloidal mixture. The colloids in the colloidal mixture had an average particle size of about 642.7 nm and a zeta potential of about 9.8 mV. The colloidal mixture gelled in 2 hours at room temperature (25° C.).

TABLE 1 average zeta particle size potential (nm) (mV) stability Example 1 199.5 15 suspension Example 2 310.8 11 suspension Comparative Example 1 227.7 4.8 gelled Comparative Example 2 493.5 2.2 gelled Comparative Example 3 642.5 5.0 gelled Comparative Example 4 645.7 9.8 gelled

As shown in Table 1, the colloids in the colloidal mixture with amine-containing polymer have an average particle size of about 150 nm to 390 nm and a zeta potential of about 7 mV to 20 mV. The colloids in the colloidal mixture with amine-containing polymer are more stable than the colloids in the colloidal mixture without amine-containing polymer. The colloidal mixture with amine-containing polymer has good processability due to its stability.

Preparation of Composite Fabric

Example 3

200 g of aluminum doped zinc oxide (Al/Zn=0.4 wt %) was dispersed into 6 g of polyethylenimine (having a weight average molecular weight of about 1800) and 800 g of dimethyl sulfoxide to form a colloidal mixture. The colloids in the colloidal mixture have an average particle size of about 240 nm and have a zeta potential of about 12 mV. The colloidal mixture was coated on a polyethylene terephthalate fiber cloth by blade coating. Following drying, a composite fabric was obtained. The aluminum doped zinc oxide had an amount of 0.15 parts by weight base on 100 parts by weight of the fabric substrate. A TN-037 infrared-induced temperature-rising test was conducted on the composite fabric and the fabric substrate (polyethylene terephthalate fiber cloth), the results of which are shown in table 2. The infrared absorption test (the infrared ranges from about 1000 nm to about 2500 nm) was conducted on the composite fabric and the fabric substrate, the results of which are shown in table 2.

Example 4

200 g of gallium doped zinc oxide (Ga/Zn=5.0 wt %) was dispersed into 20 g of polyethylenimine (having a weight average molecular weight of about 10000) and 800 g of dimethylacetamide to form a colloidal mixture. The colloids in the colloidal mixture have an average particle size of about 199 nm and have a zeta potential of about 15 mV. The colloidal mixture was coated on a nylon fiber cloth by blade coating. Following drying, a composite fabric was obtained. The gallium doped zinc oxide had an amount of 1.5 parts by weight base on 100 parts by weight of the fabric substrate. A TN-037 infrared-induced temperature-rising test was conducted on the composite fabric and the fabric substrate (nylon fiber cloth), the results of which are shown in table 2. The infrared absorption test (the infrared ranges from about 1000 nm to about 2500 nm) was conducted on the composite fabric and the fabric substrate, the results of which are shown in table 2.

Example 5

100 g of gallium doped zinc oxide (Ga/Zn=0.5 wt %) was dispersed into 15 g of polyethylenimine (having a weight average molecular weight of about 10000) and 150 g of dimethylacetamide to form a colloidal mixture. The colloids in the colloidal mixture have an average particle size of about 310 nm and have a zeta potential of about 9 mV.

The colloidal mixture, polyurethane and dimethylacetamide were mixed to form a mixture solution. The colloidal mixture and polyurethane was mixed in a weight ratio of about 1:4. The mixture solution was coated on a releasing paper by roller coating. Following drying, a film was obtained. The film was transferred to acrylic/nylon/rayon/wool blended fiber cloth (weight ratio was about 61:18:15:6) by heat press laminating at about 120° C. to form a composite fabric. The gallium doped zinc oxide had an amount of 5 parts by weight base on 100 parts by weight of the fabric substrate. A TN-037 infrared-induced temperature-rising test was conducted on the composite fabric and the fabric substrate (acrylic/nylon/rayon/wool blended fiber cloth), the results of which are shown in table 2. The infrared absorption test (the infrared ranges from about 1000 nm to about 2500 nm) was conducted on the composite fabric and the fabric substrate, the results of which are shown in table 2.

Example 6

100 g of gallium doped zinc oxide (Ga/Zn=1.2 wt %) was dispersed into 20 g of polyethylenimine (having a weight average molecular weight of about 9000) and 400 g of dimethylformamide to form a colloidal mixture. The colloids in the colloidal mixture had an average particle size of about 350 nm and have a zeta potential of about 10 mV.

The colloidal mixture, polyurethane and dimethylformamide were mixed to form a mixture solution. The colloidal mixture and polyurethane was mixed in a weight ratio of about 1:4. The mixture solution was coated on a releasing paper by roller coating. Following drying, a film was obtained. The film was transferred to rayon/cotton blended fiber cloth (weight ratio was about 60:40) by heat press laminating at about 120° C. to form a composite fabric. The gallium doped zinc oxide had an amount of 0.15 parts by weight base on 100 parts by weight of the fabric substrate. A TN-037 infrared-induced temperature-rising test was conducted on the composite fabric and the fabric substrate (acrylic/nylon/rayon/wool blended fiber cloth), the results of which are shown in table 2. The infrared absorption test (the infrared ranges from about 1000 nm to about 2500 nm) was conducted on the composite fabric and the fabric substrate, the results of which are shown in table 2.

TABLE 2 temperature of sample (° C.) IR (after it has been absorption sample subjected to IR radiation) (%) fabric substrate 44.5 50.0 of Example 3 composite fabric 46.6 59.0 of Example 3 (temperature (IR absorption rising 2.1° C.) rising 9% ) fabric substrate 45.3 52.0 of Example 4 composite fabric 51.0 66.0 of Example 4 (temperature (IR absorption rising 5.7° C.) rising 14%) fabric substrate 44.0 48.0 of Example 5 composite fabric 52.5 66.0 of Example 5 (temperature (IR absorption rising 8.5° C.) rising 18%) fabric substrate 43.5 49.0 of Example 6 composite fabric 46.7 59.0 of Example 6 (temperature (IR absorption rising 3.2° C.) rising 10%)

As shown in Table 2, the composite fabric exhibits warmth-retention properties, and it exhibits an infrared-induced temperature rise of almost 10° C. and an infrared absorptivity rise of almost 20% more than the fabric substrate.

The composite fabric is useful in keeping the wearer warm, thus providing the wearer comfort in cold environments. A textile article is made of the composite fabric and exhibits warmth-retention effects to keep the wearer warm. The article may comprise underwear, outerwear, pantyhose, panties, tights, hosiery, stockings, socks, body-wear, shirts, pants, dresses, suits, sweaters, sports-wear, sport clothes, bedding, and sleeping bags.

It will be clear that various modifications and variations can be made to the disclosed methods and materials. It is intended that the specification and examples be considered as exemplary only, with the true scope of the disclosure being indicated by the following claims and their equivalents. 

What is claimed is:
 1. A composite fabric, comprising: a fabric substrate; and a material layer comprising a mixture on the fabric substrate, wherein the mixture comprises: an amine-containing polymer comprising polyethylenimine, derivatives of polyethylenimine, or a combination thereof, wherein the derivatives of polyethylenimine comprise ethoxyl group terminated polyethylenimine, carboxylic acid group terminated polyethylenimine, isocyanate group terminated polyethylenimine, or a combination thereof; and a powder in the amine-containing polymer, wherein the powder comprises doped zinc oxide, indium tin oxide, doped indium tin oxide, or a combination thereof, wherein the amine-containing polymer has an amount of 0.1 to 40 parts by weight base on 100 parts by weight of the powder.
 2. The composite fabric as claimed in claim 1, wherein the mixture further comprises a polymer matrix.
 3. The composite fabric as claimed in claim 2, wherein the material layer is a film.
 4. The composite fabric as claimed in claim 2, wherein the polymer matrix has an amount of 50 to 10000 parts by weight base on 100 parts by weight of the powder.
 5. The composite fabric as claimed in claim 2, wherein the polymer matrix comprises polyurethane, polyacrylate, or a combination thereof.
 6. The composite fabric as claimed in claim 1, wherein the doped zinc oxide or doped indium tin oxide has a doped element of a Group IIIB element, iron, or a combination thereof.
 7. The composite fabric as claimed in claim 6, wherein the Group IIIB element comprises gallium, aluminum, or a combination thereof.
 8. The composite fabric as claimed in claim 6, wherein the doped element of the doped zinc oxide or doped indium tin oxide has an amount of 0.1 to 20 parts by weight base on 100 parts by weight of zinc oxide or indium tin oxide.
 9. The composite fabric as claimed in claim 1, wherein the amine-containing polymer has a weight average molecular weight of from 500 to
 100000. 10. The composite fabric as claimed in claim 1, wherein the powder has an amount of 0.1 to 15 parts by weight base on 100 parts by weight of the fabric substrate.
 11. The composite fabric as claimed in claim 1, wherein the fabric substrate comprises polyethylene fiber cloth, polypropylene fiber cloth, polyamide fiber cloth, polyester fiber cloth, cotton fiber cloth, rayon fiber cloth, acetyl fiber cloth, wool fiber cloth, or a combination thereof. 